Sacrificial coating for intermediate transfer member of an indirect printing apparatus

DETAILED DESCRIPTION

0001Field of the Disclosure

0002This disclosure relates generally to indirect inkjet printers, and in particular, to a sacrificial coating employed on an intermediate transfer member of an inkjet printer.

0003Background

0004In aqueous ink indirect printing, an aqueous ink is jetted on to an intermediate imaging surface (sometimes referred to herein as an intermediate transfer member), which can be in the form of a blanket. The ink is partially dried on the blanket prior to transfixing the image to a media substrate, such as a sheet of paper. To ensure excellent print quality it is desirable that the ink drops jetted onto the blanket spread and become well-coalesced prior to drying. Otherwise, the ink images appear grainy and have deletions. Lack of spreading can also cause missing or failed inkjets in the printheads to produce streaks in the ink image. Spreading of aqueous ink is facilitated by materials having a high energy surface.

0005In order to facilitate transfer of the ink image from the blanket to the media substrate after the ink is dried on the intermediate imaging surface, a blanket having a surface with a relatively low surface energy is preferred. Rather than providing the desired spreading of ink, low surface energy materials tend to promote “beading” of individual ink drops on the image receiving surface.

0006Thus, an optimum blanket for an indirect image transfer process must tackle both the challenges of wet image quality, including desired spreading and coalescing of the wet ink; and the image transfer of the dried ink. The first challenge, wet image quality, prefers a high surface energy blanket that causes the aqueous ink to spread and wet the surface. The second challenge, image transfer, prefers a low surface energy blanket so that the ink, once partially dried, has minimal attraction to the blanket surface and can be transferred to the media substrate.

0007Various approaches have been investigated to provide a solution that balances the above challenges. These approaches include blanket material selection, ink design and auxiliary fluid methods. With respect to material selection, materials that are known to provide optimum release properties include the classes of silicone, fluorosilicone, a fluoropolymer, such as TEFLON or VITON, and certain hybrid materials. These materials have low surface energy, but provide poor wetting. Alternatively, polyurethane and polyimide have been used to improve wetting, but at the cost of ink release properties. Tuning ink compositions to address these challenges has proven to be very difficult since the primary performance attribute of the ink is the performance in the print head. For instance, if the ink surface tension is too high it will not jet properly and it if is too low it will drool out of the face plate of the print head.

0008Identifying and developing new techniques and/or materials that improve wet image quality and/or image transfer would be considered a welcome advance in the art.

SUMMARY

0009An embodiment of the present disclosure is directed to a sacrificial coating composition for an image transfer member in an aqueous ink imaging system. The coating composition is made from ingredients comprising: a latex comprising polymer particles dispersed in a continuous liquid phase; at least one hygroscopic material; at least one oil-in-water emulsion; and at least one surfactant.

0010Another embodiment of the present disclosure is directed to an indirect printing apparatus. The apparatus comprises an intermediate transfer member. A sacrificial coating is on the intermediate transfer member. The sacrificial coating is made from ingredients comprising: a latex comprising polymer particles dispersed in a continuous liquid phase; at least one hygroscopic material; at least one oil-in-water emulsion; and at least one surfactant. The apparatus further comprises a coating mechanism for forming the sacrificial coating onto the intermediate transfer member and a drying station for drying the sacrificial coating. At least one ink jet nozzle is positioned proximate the intermediate transfer member and configured for jetting ink droplets onto the sacrificial coating formed on the intermediate transfer member. An ink processing station is configured to at least partially dry the ink on the sacrificial coating formed on the intermediate transfer member. The apparatus further comprises a substrate transfer mechanism for moving a substrate into contact with the intermediate transfer member.

0011Yet another embodiment of the present disclosure is directed to an indirect printing process. The process comprises providing an ink composition to an inkjet printing apparatus comprising an intermediate transfer member. A sacrificial coating is formed onto the intermediate transfer member. The sacrificial coating is made from ingredients comprising: a latex comprising polymer particles dispersed in a continuous liquid phase; at least one hygroscopic material; at least one oil-in-water emulsion; and at least one surfactant. Droplets of ink are ejected in an imagewise pattern onto the sacrificial coating. The ink is at least partially dried to form a substantially dry ink pattern on the intermediate transfer member. Both the substantially dry ink pattern and the sacrificial coating are transferred from the intermediate transfer member to a final substrate.

0012The polymer coating compositions of the present disclosure can provide one or more of the following advantages: coatings having good wettability on, for example a fluorinated polymer substrate, coatings having good ink wetting, good ink spreading, good ink pinning, image transfer member coatings exhibiting improved wet image quality and/or improved image transfer with aqueous inks, improved physical robustness or increased shelf life and/or functions as a robust overcoat yielding prints that are mechanically robust, good wear, good scratch resistance, exhibit good water fastness and/or are not susceptible to biodegradation.

0013It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present teachings, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

0014The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present teachings and together with the description, serve to explain the principles of the present teachings.

0015<figref idref="DRAWINGS">FIG. 1</figref> is a schematic drawing of an aqueous indirect inkjet printer that prints sheet media, according to an embodiment of the present disclosure.

0016<figref idref="DRAWINGS">FIG. 2</figref> is a schematic drawing of a surface maintenance unit that applies a hydrophilic sacrificial coating composition to a surface of an intermediate transfer member in an inkjet printer, according to an embodiment of the present disclosure.

0017<figref idref="DRAWINGS">FIG. 3</figref> is a block diagram of a process for printed images in an indirect inkjet printer that uses aqueous inks, according to an embodiment of the present disclosure.

0018<figref idref="DRAWINGS">FIG. 4A</figref> is a side view of a hydrophilic sacrificial coating composition that is formed on the surface of an intermediate transfer member in an inkjet printer, according to an embodiment of the present disclosure.

0019<figref idref="DRAWINGS">FIG. 4B</figref> is a side view of dried or semi-dried hydrophilic sacrificial coating composition on the surface of the intermediate transfer member after a dryer removes a portion of a liquid vehicle in the hydrophilic sacrificial coating composition, according to an embodiment of the present disclosure.

0020<figref idref="DRAWINGS">FIG. 4C</figref> is a side view of a portion of an aqueous ink image that is formed on the dried or semi-dried hydrophilic sacrificial coating composition on the surface of the intermediate transfer member, according to an embodiment of the present disclosure.

0021<figref idref="DRAWINGS">FIG. 4D</figref> is a side view of a portion of the aqueous ink image that is formed on the dried hydrophilic sacrificial coating composition after a dryer in the printer removes a portion of the water in the aqueous ink, according to an embodiment of the present disclosure.

0022<figref idref="DRAWINGS">FIG. 4E</figref> is a side view of a print medium that receives the aqueous ink image and a portion of the dried layer of the hydrophilic composition after a transfix operation in the inkjet printer, according to an embodiment of the present disclosure.

0023<figref idref="DRAWINGS">FIG. 5</figref> shows optical microscope images taken of sacrificial coatings, as described in the examples below.

0024<figref idref="DRAWINGS">FIG. 6</figref> shows images of ink transfer test results, as discussed in the examples below.

0025It should be noted that some details of the figure have been simplified and are drawn to facilitate understanding of the embodiments rather than to maintain strict structural accuracy, detail, and scale.

DESCRIPTION OF THE EMBODIMENTS

0026Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals have been used throughout to designate identical elements. In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration a specific exemplary embodiment in which the present teachings may be practiced. The following description is, therefore, merely exemplary.

0027As used herein, the terms “printer,” “printing device,” or “imaging device” generally refer to a device that produces an image on print media with aqueous ink and may encompass any such apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, or the like, which generates printed images for any purpose. Image data generally include information in electronic form which are rendered and used to operate the inkjet ejectors to form an ink image on the print media. These data can include text, graphics, pictures, and the like. The operation of producing images with colorants on print media, for example, graphics, text, photographs, and the like, is generally referred to herein as printing or marking. Aqueous inkjet printers use inks that have a high percentage of water relative to the amount of colorant and/or liquid vehicle in the ink.

0028The term “printhead” as used herein refers to a component in the printer that is configured with inkjet ejectors to eject ink drops onto an image receiving surface. A typical printhead includes a plurality of inkjet ejectors that eject ink drops of one or more ink colors onto the image receiving surface in response to firing signals that operate actuators in the inkjet ejectors. The inkjets are arranged in an array of one or more rows and columns. In some embodiments, the inkjets are arranged in staggered diagonal rows across a face of the printhead. Various printer embodiments include one or more printheads that form ink images on an image receiving surface. Some printer embodiments include a plurality of printheads arranged in a print zone. An image receiving surface, such as an intermediate imaging surface, moves past the printheads in a process direction through the print zone. The inkjets in the printheads eject ink drops in rows in a cross-process direction, which is perpendicular to the process direction across the image receiving surface.

0029As used in this document, the term “aqueous ink” includes liquid inks in which colorant is in a solution, suspension or dispersion with a liquid vehicle that includes water and/or one or more liquid vehicles. The term “liquid vehicle” is defined herein to include both liquid solvents that may dissolve a solute into a solution and liquid carriers that hold particles in a suspension or dispersion without dissolving the particle.

0030As used herein, the term “hydrophilic” refers to any composition or compound that attracts water molecules or other solvents or liquid carriers used in aqueous ink. As used herein, a reference to a hydrophilic composition refers to a liquid vehicle that carries a hydrophilic agent. Examples of liquid vehicles include, but are not limited to a liquid, such as water or alcohol, that carries a dispersion, suspension, or solution.

0031As used herein, a reference to a dried layer or dried coating refers to an arrangement of a hydrophilic compound after all or a substantial portion of the liquid vehicle has been removed from the composition through a drying process. As described in more detail below, an indirect inkjet printer forms a layer of a hydrophilic composition on a surface of an intermediate transfer member using a liquid vehicle, such as water, to apply a layer of the hydrophilic composition. The liquid vehicle is used as a mechanism to convey the hydrophilic composition to an image receiving surface to form a uniform layer of the hydrophilic composition on the image receiving surface.

0032An embodiment of the present disclosure is directed to a liquid sacrificial coating composition for an image transfer member in an aqueous ink imaging system. The coating composition includes a latex comprising polymer particles dispersed in a continuous liquid phase; at least one hygroscopic material; at least one oil-in-water emulsion; and at least one surfactant.

0033The polymer particles comprise one or more repeating polymeric units. In an embodiment, the polymeric units are selected from the group consisting of acrylic acid units, acrylate units, methacrylic acid units, methacrylate units, diene units, aliphatic nitrile units, vinyl ether units, vinyl ester units, vinyl ketone units, vinylidene halide units, vinyl substituted heterocyclic amine units, acrylamide units, methacrylamide units, vinyl substituted aromatic hydrocarbon units, vinyl halide units and alkene units. In an embodiment, the polymer particles comprise a polyvinyl acetate copolymer. In an embodiment, the latex is an acrylic latex, such as a latex comprising one or more acrylic resins made from at least one monomer selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate, methacrylic acid and acrylic acid. In an embodiment, the latex polymer particles comprise one or more repeating polymeric units selected from the group consisting of n-butyl acrylate units, methacrylic acid units, methyl methacrylate units, styrene units and butadiene units. In an embodiment, the latex is a styrene/n-butyl acrylate/methacrylic acid terpolymer, examples of which are disclosed in co-pending U.S. patent application Ser. No. 14/288,633, filed on May 28, 2014, the disclosure of which is incorporated herein by reference in its entirety. Examples of suitable latexes can include well known latexes such as Styrene/n-butyl acrylate latex, which has been commercially used, for example, in aqueous overcoats in post finishing processes.

0034The monomers and amounts of monomers employed in the latex can be adjusted to provide desired properties for the transfix process. For instance, acrylic latex and/or styrene butadiene latex can be employed with different methacrylic acid (MAA) loadings to alter the properties of the latex. In one example, different methacrylic acid loadings were employed for different styrene to n-butyl acrylate ratios to provide very different glass transition temperatures and softening points. An example of loading of methacrylic acid relative to styrene and n-butyl acrylate in these latexes ranges from about 2 to about 20 wt %, such as about 5 wt %, 10 wt % or 15 wt %, relative to the total weight of the methacrylic acid, styrene and n-butyl acrylate monomers.

0035The latexes can have any suitable solids content. Examples of suitable solids content include ranges from about 5% to about 60% by weight, such as about 10% to about 50% by weight, or about 20% to about 40% by weight, relative to the total weight of the liquid coating composition.

0036The latex polymer can have any suitable molecular weight. Examples of suitable weight average molecular weight, Mw, range from about 3000 to about 300,000, such as about 5,000 to 100,000, or about 5,000 to about 60,000. Examples of suitable number average molecular weight, Mn, range from about 1,000 to about 30,000, such as about 2,000 to 20,000, or about 5,000 to about 15,000.

0037Latex properties can be adjusted to provide any desired properties suitable for the aqueous transfix printing process. For example, the Tg of the latex can range from about −45° C. to about 100° C., such as about −35° C. to 85° C., or about −25° C. to about 55° C. In an example, the viscosity of the latex is from about 3 cps to 800 cps at 25° C. In an example, the pH of the latex ranges from about 1.5 to about 10, such as about 3 to about 8. In an example, the softening point of the latex ranges from about 100° C. to about 170° C.

0038In an example, the D50 particle size of the latex ranges from about 20 to about 200 nm and the particle size distribution ranges from about 5 nm to 300 nm, such as about 50 to about 250 nm. The gel content (insoluble portion in toluene) in the latex ranges, for example, from 0 to about 20.0%

0039The chemical structure of the latex containing coating can be tailored to fine-tune the wettability and release characteristics of the sacrificial coating from the underlying ITM surface. This can be accomplished by employing one or more hygroscopic materials and one or more surfactants in the coating composition.

0040Any suitable hygroscopic material can be employed. The hygroscopic material can be functionalized as a plasticizer. In an embodiment, the at least one hygroscopic material is selected from the group consisting of glycerol, sorbitol, glycols such as polyethylene glycol, vinyl alcohols, xylitol, maltitol, polymeric polyols, glyceryl triacetate, glycouril, ionic liquids and mixtures thereof. A single hygroscopic material can be used. Alternatively, multiple hygroscopic materials, such as two, three or more hygroscopic materials, can be used.

0041The addition of an oil-in-water emulsion to the undercoat formulation can further improve the ink transfer efficiency during the transfix process. In an embodiment, the oil-in-water emulsion includes a surfactant. Any suitable oil and surfactant combination that will provide the desired improvement in ink transfer efficiency can be employed.

0042Examples of oils include silicone oils, perfluoroether oils, hydrocarbon oils and mixtures thereof. In an embodiment, the oil is mineral oil selected from the group consisting of paraffinic oils, naphthenic oils, aromatic oils and mixtures thereof. Oil viscosity can range, for example, from about 10 cps to about 1000 cps, such as about 100 cps to about 900 cps, or about 200 cps to about 800 cps. In an embodiment, the viscosity of silicone oil is less than 1000 centipoises.

0043Any suitable surfactants can be employed. In an embodiment, the at least one surfactant is nonionic surfactant having a hydrophile lipophile balance (“HLB”) value ranging from about 4 to about 15, such as, for example about 8 to about 14. A single surfactant can be used. Alternatively, multiple surfactants, such as two, three or more surfactants, can be used. For example, the surfactant can comprise a mixture of a first surfactant and a second surfactant, the first surfactant having an HLB value ranging from about 8 or 10 to about 14 or 15 and the second surfactant having an HLB value ranging from about 4 to about 8 or 10, the first surfactant having a higher HLB value than the second surfactant.

0044In an embodiment, the surfactant can be a nonionic linear or branched alcohol ethoxylate compound of general formula RO(CH₂CH₂O)_xH, where R is an alkyl group ranging from C₆to C₁₈and x is a positive integer ranging from 1 to 15. Other examples of suitable surfactants include polyethylene glycol and polyethylene glycol trimethylnonyl ether. Examples of nonionic surfactants include secondary alcohol ethoxylates such as the Tergitol® 15-S series supplied by Dow Chemical Company. In an embodiment, the surfactants are branched secondary alcohol ethoxylates such as a branched secondary alcohol ethoxylate with 6 to 12 moles of ethylene oxide (EO). Examples of suitable commercially available surfactants include the Tergitol® TMN series also supplied by Dow Chemical Company, such as Tergitol TMN-6, a branched secondary alcohol ethoxylate and Tergitol 15-s-7, a secondary alcohol ethoxylate. Formula 1 below is a general formula for the Tergitol series. Surfactants of formula 1 could have any suitable value for n, such as, for example, 1 to 15, or 6 to 12. For TMN-6 the valued of n is about 8. TMN-10 and TMN-100 are also potential candidates, which values for n of about 11 and 10, respectively.

0045<chemistry id="CHEM-US-00001" num="00001"><img file="US9593255B2_D0001.tif" /></chemistry><br /> In an embodiment, the cloud point for the alcohol ethoxylate is above 30° C. Any other suitable surfactants can also be employed.

0046The coating composition can optionally include one or more fillers or additives. Fillers and additives can be selected to improve robustness of the sacrificial coating, among other things. Examples of suitable fillers include metal oxide particles, such as colloidal silica or nano-aluminum oxide. Other optional additives include, for example, silicone, biocides and additional solvents and/or liquid carriers. Examples of biocides include ACTICIDES® CT, ACTICIDES® LA 1209 and ACTICIDES® MBS from about 0.001 weight percent to about 0.2 weight percent of the active ingredient. Examples of suitable liquid vehicles include isopropanol and MEK (methyl ethyl ketone) or combinations thereof in water.

0047To form the sacrificial coatings, a wet coating composition as described herein is applied to the intermediate transfer member (“ITM”), where it is semi-dried or dried to form the coating. The coating can have a higher surface energy and/or be more hydrophilic than the base ITM, which is usually a material with low surface free energy, for example, a polysiloxane such as polydimethylsiloxane or other silicone rubber material, fluorosilicone, TEFLON, polyimide or combinations thereof.

0048The ingredients of the wet coating composition can be mixed in any suitable manner to form a composition that can be coated onto the intermediate transfer member. In addition to the ingredients discussed above, the mixture can include other ingredients, such as any solvents, liquid carriers and biocides mentioned herein. Methods of making the coatings of the present application are disclosed, for example, in co-pending U.S. patent application Ser. No. 14/493,569 filed Sep. 23, 2014, the disclosure of which is incorporated herein by reference in its entirety.

0049The total amount of water in the wet composition prior to coating can be any suitable amount. In an embodiment, the total amount of water can be 30% by weight or more, such as from about 40 to about 95% by weight, or about 45 to about 70% or 80% by weight, relative to the total weight of the composition.

0050The ingredients can be mixed in any suitable amounts to form the coating compositions. For example, the latex can be added in an amount of from about 1% to about 50% by weight, or from about 5% to about 40% by weight, or from about 10% or 20% to about 35% by weight based upon the total weight of the coating mixture. The at least one oil-in-water emulsion can be present in an amount ranging from about 0.05% to about 8% by weight relative to the total weight of the coating mixture, such as about 0.1% to about 6% or about 0.2% to about 1, 2 or 4%. The surfactants can be present in an amount of from about 0.01 to about 4 weight percent, or from about 0.1 to about 2 weight percent, or from about 0.2 to about 0.5 or 1 weight percent, based upon the total weight of the coating mixture. The hygroscopic material can be present in an amount of from about 0.5 to about 30, or from about 10 or 15 to about 20 or 25 weight percent, based upon the total weight of the coating mixture.

0051The compositions of the present disclosure can be used to form a sacrificial coating over any suitable substrate. Any suitable coating method can be employed, including, but not limited to, dip coating, spray coating, spin coating, flow coating, stamp printing, die extrusion coatings, flexo and gravure coating and/or blade techniques. In exemplary embodiments, suitable methods that can be employed to coat the liquid sacrificial coating composition on an intermediate transfer member include use of an anilox roller, as shown in <figref idref="DRAWINGS">FIG. 2</figref>, or an air atomization device such as an air brush or an automated air/liquid sprayer can be used for spray coating. In another example, a programmable dispenser can be used to apply the coating material to conduct a flow coating.

0052In embodiments, the wet coating can be heated at an appropriate temperature for the drying and curing, depending on the material or process used. For example, the wet coating can be heated to a temperature ranging from about 30° C. to about 200° C. for about 0.01 to about 10 seconds or from about 0.1 second to about 2 seconds. In embodiments, after the drying and curing process, the sacrificial coating can have a thickness ranging from about 0.02 micrometer to about 10 micrometers, or from about 0.02 micrometer to about 5 micrometers, or from about 0.05 micrometer to about 1 micrometers.

0053In an embodiment, the sacrificial coating can cover a portion of a major surface of the intermediate transfer member. The major outer surface of the intermediate transfer member can comprise, for example, silicone or a fluorinated polymer.

0054It has been found that the sacrificial coating reduces the wet image quality problem discussed above by providing an ink wetting surface on the intermediate transfer member. The coatings may also improve the image cohesion significantly to enable excellent image transfer.

0055<figref idref="DRAWINGS">FIG. 1</figref> illustrates a high-speed aqueous ink image producing machine or printer <b>10</b>. As illustrated, the printer <b>10</b> is an indirect printer that forms an ink image on a surface of a blanket <b>21</b> mounted about an intermediate rotating member <b>12</b> and then transfers the ink image to media passing through a nip <b>18</b> formed between the blanket <b>21</b> and the transfix roller <b>19</b>. The surface <b>14</b> of the blanket <b>21</b> is referred to as the image receiving surface of the blanket <b>21</b> and the rotating member <b>12</b> since the surface <b>14</b> receives a hydrophilic composition and the aqueous ink images that are transfixed to print media during a printing process. A print cycle is now described with reference to the printer <b>10</b>. As used in this document, “print cycle” refers to the operations of a printer to prepare an imaging surface for printing, ejection of the ink onto the prepared surface, treatment of the ink on the imaging surface to stabilize and prepare the image for transfer to media, and transfer of the image from the imaging surface to the media.

0056The printer <b>10</b> includes a frame <b>11</b> that supports directly or indirectly operating subsystems and components, which are described below. The printer <b>10</b> includes an intermediate transfer member, which is illustrated as rotating imaging drum <b>12</b> in <figref idref="DRAWINGS">FIG. 1</figref>, but can also be configured as a supported endless belt. The imaging drum <b>12</b> has an outer blanket <b>21</b> mounted about the circumference of the drum <b>12</b>. The blanket moves in a direction <b>16</b> as the member <b>12</b> rotates. A transfix roller <b>19</b> rotatable in the direction <b>17</b> is loaded against the surface of blanket <b>21</b> to form a transfix nip <b>18</b>, within which ink images formed on the surface of blanket <b>21</b> are transfixed onto a print medium <b>49</b>. In some embodiments, a heater in the drum <b>12</b> (not shown) or in another location of the printer heats the image receiving surface <b>14</b> on the blanket <b>21</b> to a temperature in a range of, for example, approximately 40° C. to approximately 70° C. The elevated temperature promotes partial drying of the liquid vehicle that is used to deposit the hydrophilic composition and of the water in the aqueous ink drops that are deposited on the image receiving surface <b>14</b>.

0057The blanket is formed of a material having a relatively low surface energy to facilitate transfer of the ink image from the surface of the blanket <b>21</b> to the print medium <b>49</b> in the nip <b>18</b>. Such materials include polysiloxanes, fluoro-silicones, polyimides, fluoropolymers such as VITON or TEFLON and the like. A surface maintenance unit (SMU) <b>92</b> removes residual ink left on the surface of the blanket <b>21</b> after the ink images are transferred to the print medium <b>49</b>. The low energy surface of the blanket does not aid in the formation of good quality ink images because such surfaces do not spread ink drops as well as high energy surfaces.

0058In an embodiment more clearly depicted in <figref idref="DRAWINGS">FIG. 2</figref>, the SMU <b>92</b> includes a coating applicator, such as a donor roller <b>404</b>, which is partially submerged in a reservoir <b>408</b> that holds a sacrificial coating composition. The donor roller <b>404</b> rotates in response to the movement of the image receiving surface <b>14</b> in the process direction. The donor roller <b>404</b> draws the liquid sacrificial coating composition from the reservoir <b>408</b> and deposits a layer of the composition on the image receiving surface <b>14</b>. As described below, the sacrificial coating composition is deposited as a uniform layer having any desired thickness. Examples include thicknesses ranging from about 0.1 μm to about 10 μm. The SMU <b>92</b> deposits the sacrificial wet coating composition on the image receiving surface <b>14</b>. After a drying process, the dried sacrificial coating substantially covers the image receiving surface <b>14</b> before the printer ejects ink drops during a print process. In some illustrative embodiments, the donor roller <b>404</b> is an anilox roller or an elastomeric roller made of a material, such as rubber. The SMU <b>92</b> can be operatively connected to a controller <b>80</b>, described in more detail below, to enable the controller to operate the donor roller, as well as a metering blade and a cleaning blade, selectively to deposit and distribute the coating material onto the surface of the blanket and to remove un-transferred ink and any sacrificial coating residue from the surface of the blanket <b>21</b>.

0059Referring back to <figref idref="DRAWINGS">FIG. 1</figref>, the printer <b>10</b> includes a dryer <b>96</b> that emits heat and optionally directs an air flow toward the sacrificial coating composition that is applied to the image receiving surface <b>14</b>. The dryer <b>96</b> facilitates the evaporation of at least a portion of the liquid vehicle from the sacrificial coating composition to leave a dried layer on the image receiving surface <b>14</b> before the intermediate transfer member passes the printhead modules <b>34</b>A-<b>34</b>D to receive the aqueous printed image.

0060The printer <b>10</b> can include an optical sensor <b>94</b>A, also known as an image-on-drum (“IOD”) sensor, which is configured to detect light reflected from the blanket surface <b>14</b> and the sacrificial coating applied to the blanket surface as the member <b>12</b> rotates past the sensor. The optical sensor <b>94</b>A includes a linear array of individual optical detectors that are arranged in the cross-process direction across the blanket <b>21</b>. The optical sensor <b>94</b>A generates digital image data corresponding to light that is reflected from the blanket surface <b>14</b> and the sacrificial coating. The optical sensor <b>94</b>A generates a series of rows of image data, which are referred to as “scanlines,” as the intermediate transfer member <b>12</b> rotates the blanket <b>21</b> in the direction <b>16</b> past the optical sensor <b>94</b>A. In one embodiment, each optical detector in the optical sensor <b>94</b>A further comprises three sensing elements that are sensitive to wavelengths of light corresponding to red, green, and blue (RGB) reflected light colors. Alternatively, the optical sensor <b>94</b>A includes illumination sources that shine red, green, and blue light or, in another embodiment, the sensor <b>94</b>A has an illumination source that shines white light onto the surface of blanket <b>21</b> and white light detectors are used. The optical sensor <b>94</b>A shines complementary colors of light onto the image receiving surface to enable detection of different ink colors using the photodetectors. The image data generated by the optical sensor <b>94</b>A can be analyzed by the controller <b>80</b> or other processor in the printer <b>10</b> to identify the thickness of the sacrificial coating on the blanket and the area coverage. The thickness and coverage can be identified from either specular or diffuse light reflection from the blanket surface and/or coating. Other optical sensors, such as <b>94</b>B, <b>94</b>C, and <b>94</b>D, are similarly configured and can be located in different locations around the blanket <b>21</b> to identify and evaluate other parameters in the printing process, such as missing or inoperative inkjets and ink image formation prior to image drying (<b>94</b>B), ink image treatment for image transfer (<b>94</b>C), and the efficiency of the ink image transfer (<b>94</b>D). Alternatively, some embodiments can include an optical sensor to generate additional data that can be used for evaluation of the image quality on the media (<b>94</b>E).

0061The printer <b>10</b> includes an airflow management system <b>100</b>, which generates and controls a flow of air through the print zone. The airflow management system <b>100</b> includes a printhead air supply <b>104</b> and a printhead air return <b>108</b>. The printhead air supply <b>104</b> and return <b>108</b> are operatively connected to the controller <b>80</b> or some other processor in the printer <b>10</b> to enable the controller to manage the air flowing through the print zone. This regulation of the air flow can be through the print zone as a whole or about one or more printhead arrays. The regulation of the air flow helps prevent evaporated solvents, liquid carriers and water in the ink from condensing on the printhead and helps attenuate heat in the print zone to reduce the likelihood that ink dries in the inkjets, which can clog the inkjets. The airflow management system <b>100</b> can also include sensors to detect humidity and temperature in the print zone to enable more precise control of the temperature, flow, and humidity of the air supply <b>104</b> and return <b>108</b> to ensure optimum conditions within the print zone. Controller <b>80</b> or some other processor in the printer <b>10</b> can also enable control of the system <b>100</b> with reference to ink coverage in an image area or even to time the operation of the system <b>100</b> so air only flows through the print zone when an image is not being printed.

0062The high-speed aqueous ink printer <b>10</b> also includes an aqueous ink supply and delivery subsystem <b>20</b> that has at least one source <b>22</b> of one color of aqueous ink. Since the illustrated printer <b>10</b> is a multicolor image producing machine, the ink delivery system <b>20</b> includes, for example, four (4) sources <b>22</b>, <b>24</b>, <b>26</b>, <b>28</b>, representing four (4) different colors CYMK (cyan, yellow, magenta, black) of aqueous inks. In the embodiment of <figref idref="DRAWINGS">FIG. 1</figref>, the printhead system <b>30</b> includes a printhead support <b>32</b>, which provides support for a plurality of printhead modules, also known as print box units, <b>34</b>A through <b>34</b>D. Each printhead module <b>34</b>A-<b>34</b>D effectively extends across the width of the blanket and ejects ink drops onto the surface <b>14</b> of the blanket <b>21</b>. A printhead module can include a single printhead or a plurality of printheads configured in a staggered arrangement. Each printhead module is operatively connected to a frame (not shown) and aligned to eject the ink drops to form an ink image on the coating on the blanket surface <b>14</b>. The printhead modules <b>34</b>A-<b>34</b>D can include associated electronics, ink reservoirs, and ink conduits to supply ink to the one or more printheads. In the illustrated embodiment, conduits (not shown) operatively connect the sources <b>22</b>, <b>24</b>, <b>26</b>, and <b>28</b> to the printhead modules <b>34</b>A-<b>34</b>D to provide a supply of ink to the one or more printheads in the modules. As is generally familiar, each of the one or more printheads in a printhead module can eject a single color of ink. In other embodiments, the printheads can be configured to eject two or more colors of ink. For example, printheads in modules <b>34</b>A and <b>34</b>B can eject cyan and magenta ink, while printheads in modules <b>34</b>C and <b>34</b>D can eject yellow and black ink. The printheads in the illustrated modules are arranged in two arrays that are offset, or staggered, with respect to one another to increase the resolution of each color separation printed by a module. Such an arrangement enables printing at twice the resolution of a printing system only having a single array of printheads that eject only one color of ink. Although the printer <b>10</b> includes four printhead modules <b>34</b>A-<b>34</b>D, each of which has two arrays of printheads, alternative configurations include a different number of printhead modules or arrays within a module.

0063After the printed image on the blanket surface <b>14</b> exits the print zone, the image passes under an image dryer <b>130</b>. The image dryer <b>130</b> includes a heater, such as a radiant infrared, radiant near infrared and/or a forced hot air convection heater <b>134</b>, a dryer <b>136</b>, which is illustrated as a heated air source <b>136</b>, and air returns <b>138</b>A and <b>138</b>B. The infrared heater <b>134</b> applies infrared heat to the printed image on the surface <b>14</b> of the blanket <b>21</b> to evaporate water or other liquid vehicles in the ink. The heated air source <b>136</b> directs heated air over the ink to supplement the evaporation of the water or liquid vehicle from the ink. In one embodiment, the dryer <b>136</b> is a heated air source with the same design as the dryer <b>96</b>. While the dryer <b>96</b> is positioned along the process direction to dry the hydrophilic composition, the dryer <b>136</b> is positioned along the process direction after the printhead modules <b>34</b>A-<b>34</b>D to at least partially dry the aqueous ink on the image receiving surface <b>14</b>. The air is then collected and evacuated by air returns <b>138</b>A and <b>138</b>B to reduce the interference of the air flow with other components in the printing area.

0064As further shown, the printer <b>10</b> includes a print medium supply and handling system <b>40</b> that stores, for example, one or more stacks of paper print mediums of various sizes. The print medium supply and handling system <b>40</b>, for example, includes sheet or substrate supply sources <b>42</b>, <b>44</b>, <b>46</b>, and <b>48</b>. In the embodiment of printer <b>10</b>, the supply source <b>48</b> is a high capacity paper supply or feeder for storing and supplying image receiving substrates in the form of cut print mediums <b>49</b>, for example. The print medium supply and handling system <b>40</b> also includes a substrate handling and transport system <b>50</b> that has a media pre-conditioner assembly <b>52</b> and a media post-conditioner assembly <b>54</b>. The printer <b>10</b> includes an optional fusing device <b>60</b> to apply additional heat and pressure to the print medium after the print medium passes through the transfix nip <b>18</b>. In the embodiment of <figref idref="DRAWINGS">FIG. 1</figref>, the printer <b>10</b> includes an original document feeder <b>70</b> that has a document holding tray <b>72</b>, document sheet feeding and retrieval devices <b>74</b>, and a document exposure and scanning system <b>76</b>.

0065Operation and control of the various subsystems, components and functions of the machine or printer <b>10</b> are performed with the aid of a controller or electronic subsystem (ESS) <b>80</b>. The ESS or controller <b>80</b> is operably connected to the intermediate transfer member <b>12</b>, the printhead modules <b>34</b>A-<b>34</b>D (and thus the printheads), the substrate supply and handling system <b>40</b>, the substrate handling and transport system <b>50</b>, and, in some embodiments, the one or more optical sensors <b>94</b>A-<b>94</b>E. The ESS or controller <b>80</b>, for example, is a self-contained, dedicated mini-computer having a central processor unit (CPU) <b>82</b> with electronic storage <b>84</b>, and a display or user interface (UI) <b>86</b>. The ESS or controller <b>80</b>, for example, includes a sensor input and control circuit <b>88</b> as well as a pixel placement and control circuit <b>89</b>. In addition, the CPU <b>82</b> reads, captures, prepares and manages the image data flow between image input sources, such as the scanning system <b>76</b>, or an online or a work station connection <b>90</b>, and the printhead modules <b>34</b>A-<b>34</b>D. As such, the ESS or controller <b>80</b> is the main multi-tasking processor for operating and controlling all of the other machine subsystems and functions, including the printing process discussed below.

0066The controller <b>80</b> can be implemented with general or specialized programmable processors that execute programmed instructions. The instructions and data required to perform the programmed functions can be stored in memory associated with the processors or controllers. The processors, their memories, and interface circuitry configure the controllers to perform the operations described below. These components can be provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with discrete components or circuits provided in very large scale integrated (VLSI) circuits. Also, the circuits described herein can be implemented with a combination of processors, ASICs, discrete components, or VLSI circuits.

0067Although the printer <b>10</b> in <figref idref="DRAWINGS">FIG. 1</figref> is described as having a blanket <b>21</b> mounted about an intermediate rotating member <b>12</b>, other configurations of an image receiving surface can be used. For example, the intermediate rotating member can have a surface integrated into its circumference that enables an aqueous ink image to be formed on the surface. Alternatively, a blanket is configured as an endless rotating belt for formation of an aqueous image. Other variations of these structures can be configured for this purpose. As used in this document, the term “intermediate imaging surface” includes these various configurations.

0068Once an image or images have been formed on the blanket and coating under control of the controller <b>80</b>, the illustrated inkjet printer <b>10</b> operates components within the printer to perform a process for transferring and fixing the image or images from the blanket surface <b>14</b> to media. In the printer <b>10</b>, the controller <b>80</b> operates actuators to drive one or more of the rollers <b>64</b> in the media transport system <b>50</b> to move the print medium <b>49</b> in the process direction P to a position adjacent the transfix roller <b>19</b> and then through the transfix nip <b>18</b> between the transfix roller <b>19</b> and the blanket <b>21</b>. The transfix roller <b>19</b> applies pressure against the back side of the print medium <b>49</b> in order to press the front side of the print medium <b>49</b> against the blanket <b>21</b> and the intermediate transfer member <b>12</b>. Although the transfix roller <b>19</b> can also be heated, in the exemplary embodiment of <figref idref="DRAWINGS">FIG. 1</figref>, the transfix roller <b>19</b> is unheated. Instead, the pre-heater assembly <b>52</b> for the print medium <b>49</b> is provided in the media path leading to the nip. The pre-conditioner assembly <b>52</b> conditions the print medium <b>49</b> to a predetermined temperature that aids in the transferring of the image to the media, thus simplifying the design of the transfix roller. The pressure produced by the transfix roller <b>19</b> on the back side of the heated print medium <b>49</b> facilitates the transfixing (transfer and fusing) of the image from the intermediate transfer member <b>12</b> onto the print medium <b>49</b>. The rotation or rolling of both the intermediate transfer member <b>12</b> and transfix roller <b>19</b> not only transfixes the images onto the print medium <b>49</b>, but also assists in transporting the print medium <b>49</b> through the nip. The intermediate transfer member <b>12</b> continues to rotate to enable the printing process to be repeated.

0069After the intermediate transfer member moves through the transfix nip <b>18</b>, the image receiving surface passes a cleaning unit that removes residual portions of the sacrificial coating and small amounts of residual ink from the image receiving surface <b>14</b>. In the printer <b>10</b>, the cleaning unit is embodied as a cleaning blade <b>95</b> that engages the image receiving surface <b>14</b>. The blade <b>95</b> is formed from a material that wipes the image receiving surface <b>14</b> without causing damage to the blanket <b>21</b>. For example, the cleaning blade <b>95</b> is formed from a flexible polymer material in the printer <b>10</b>. As depicted below in <figref idref="DRAWINGS">FIG. 1</figref>, another embodiment has a cleaning unit that includes a roller or other member that applies a mixture of water and detergent to remove residual materials from the image receiving surface <b>14</b> after the intermediate transfer member moves through the transfix nip <b>18</b>. As used herein, the term “detergent” or cleaning agent refers to any surfactant, liquid vehicle, or other chemical compound that is suitable for removing any sacrificial coating and any residual ink that may remain on the image receiving surface from the image receiving surface. One example of a suitable detergent is sodium stearate, which is a compound commonly used in soap. Another example is IPA, which is common solvent that is very effective to remove ink residues from the image receiving surface. In an embodiment, no residue of the sacrificial coating layer remains on the ITM after transferring the ink and sacrificial layer, in which case cleaning of the ITM to remove residual sacrificial coating may not be an issue.

0070<figref idref="DRAWINGS">FIG. 3</figref> depicts a process <b>700</b> for operating an aqueous indirect inkjet printer using a sacrificial coating composition comprising latex, as described herein, to form a dried coating on an image receiving surface of an intermediate transfer member prior to ejecting liquid ink drops onto the dried layer. In the discussion below, a reference to the process <b>700</b> performing an action or function refers to a controller, such as the controller <b>80</b> in the printer <b>10</b>, executing stored programmed instructions to perform the action or function in conjunction with other components of the printer. The process <b>700</b> is described in conjunction with <figref idref="DRAWINGS">FIG. 1</figref> showing the printer <b>10</b>, and <figref idref="DRAWINGS">FIG. 4A</figref>-<figref idref="DRAWINGS">FIG. 4E</figref> showing the blanket and coatings, for illustrative purposes. The sacrificial coatings and processes of employing these coatings are not limited to use with printer <b>10</b>, but can potentially be employed with any inkjet printer comprising an intermediate transfer member, as would be readily understood by one of ordinary skill in the art.

0071Process <b>700</b> begins as the printer applies a layer of a sacrificial composition with a liquid vehicle to the image receiving surface of the intermediate transfer member (block <b>704</b>). In the printer <b>10</b>, the drum <b>12</b> and blanket <b>21</b> move in the process direction along the indicated circular direction <b>16</b> during the process <b>700</b> to receive the sacrificial coating composition.

0072In an embodiment, the liquid vehicle is water or another liquid, such as alcohol, which partially evaporates from the image receiving surface and leaves a dried layer on the image receiving surface. In <figref idref="DRAWINGS">FIG. 4A</figref>, the surface of the intermediate transfer member <b>504</b> is covered with the sacrificial coating composition <b>508</b>. The SMU <b>92</b> deposits the sacrificial coating composition on the image receiving surface <b>14</b> of the blanket <b>21</b> to form a uniform hydrophilic coating. A greater coating thickness of the sacrificial coating composition enables formation of a uniform layer that completely covers the image receiving surface, but the increased volume of liquid vehicle in the thicker coating requires additional drying time or larger dryers to remove the liquid vehicle to form a dried layer. Thinner coatings of the sacrificial coating composition require the removal of a smaller volume of the liquid vehicle to form the dried layer, but if the sacrificial coating is too thin, then the coating may not fully cover the image receiving surface. In certain embodiments the sacrificial coating composition with the liquid vehicle is applied at a thickness of between approximately 1 μm and 10 μm.

0073Process <b>700</b> continues as a dryer in the printer dries the sacrificial coating composition to remove at least a portion of the liquid vehicle and to form a dried layer on the image receiving surface (block <b>708</b>). In the printer <b>10</b> the dryer <b>96</b> applies radiant heat and optionally includes a fan to circulate air onto the image receiving surface of the drum <b>12</b> or belt <b>13</b>. <figref idref="DRAWINGS">FIG. 4B</figref> depicts the dried layer <b>512</b>. The dryer <b>96</b> removes of a portion of the liquid vehicle, which decreases the thickness of the layer of dried layer that is formed on the image receiving surface. In the printer <b>10</b> the thickness of the dried layer <b>512</b> can be any suitable desired thickness. Example thicknesses range from about 0.1 μm to about 3 μm in different embodiments, and in certain specific embodiments from about 0.1 to about 0.5 μm.

0074The dried sacrificial coating <b>512</b> is also referred to as a “skin” layer. The dried sacrificial coating <b>512</b> has a uniform thickness that covers substantially all of the portion of the image receiving surface that receives aqueous ink during a printing process. As described above, while the wet sacrificial coating composition includes solutions, suspension, or dispersion of the sacrificial coating material in a liquid vehicle, the dried sacrificial coating <b>512</b> covers the image receiving surface of intermediate transfer member <b>504</b>. The dried sacrificial coating <b>512</b> has a comparatively high level of adhesion to the image receiving surface of intermediate transfer member <b>504</b>, and a comparatively low level of adhesion to a print medium that contacts the dried layer <b>512</b>. As described in more detail below, when aqueous ink drops are ejected onto portions of the dried layer <b>512</b>, a portion of the water and other liquid vehicles in the aqueous ink permeates the dried layer <b>512</b>.

0075Process <b>700</b> continues as the image receiving surface with the hydrophilic skin layer moves past one or more printheads that eject aqueous ink drops onto the dried layer and the image receiving surface to form a latent aqueous printed image (block <b>712</b>). The printhead modules <b>34</b>A-<b>34</b>D in the printer <b>10</b> eject ink drops in the CMYK colors to form the printed image.

0076The sacrificial coating <b>512</b> is substantially impermeable to the colorants in the ink <b>524</b>, and the colorants remain on the surface of the dried layer <b>512</b> where the aqueous ink spreads. The spread of the liquid ink enables neighboring aqueous ink drops to merge together on the image receiving surface instead of beading into individual droplets as occurs in traditional low-surface energy image receiving surfaces.

0077Referring again to <figref idref="DRAWINGS">FIG. 3</figref>, the process <b>700</b> continues with a partial drying process of the aqueous ink on the intermediate transfer member (block <b>716</b>). The drying process removes a portion of the water from the aqueous ink and the sacrificial coating, also referred to as the skin layer, on the intermediate transfer member so that the amount of water that is transferred to a print medium in the printer does not produce cockling or other deformations of the print medium. In the printer <b>10</b>, the heated air source <b>136</b> directs heated air toward the image receiving surface <b>14</b> to dry the printed aqueous ink image. In some embodiments, the intermediate transfer member and blanket are heated to an elevated temperature to promote evaporation of liquid from the ink. For example, in the printer <b>10</b>, the imaging drum <b>12</b> and blanket <b>21</b> are heated to a temperature ranging from about 40° C. to about 70° C. to enable partial drying of the ink in the dried layer during the printing process. As depicted in <figref idref="DRAWINGS">FIG. 4D</figref>, the drying process forms a partially dried aqueous ink <b>532</b> that retains a reduced amount of water compared to the freshly printed aqueous ink image of <figref idref="DRAWINGS">FIG. 4C</figref>.

0078The drying process increases the viscosity of the aqueous ink, which changes the consistency of the aqueous ink from a low-viscosity liquid to a higher viscosity tacky material. The drying process also reduces the thickness of the ink <b>532</b>. The drying process removes sufficient water so that the ink is substantially dry. In an embodiment, the substantially dry ink contains less that 5% water and other liquid vehicles by weight, such as less than 2% water and other liquid vehicles, or even less than 1% water and other liquid vehicles, by weight of the ink.

0079Process <b>700</b> continues as the printer transfixes the latent aqueous ink image from the image receiving surface to a print medium, such as a sheet of paper (block <b>720</b>). In the printer <b>10</b>, the image receiving surface <b>14</b> of the drum <b>12</b> engages the transfix roller <b>19</b> to form a nip <b>18</b>. A print medium, such as a sheet of paper, moves through the nip between the drum <b>12</b> and the transfix roller <b>19</b>. The pressure in the nip transfers the latent aqueous ink image and a portion of the dried layer to the print medium. After passing through the transfix nip <b>18</b>, the print medium carries the printed aqueous ink image. As depicted in <figref idref="DRAWINGS">FIG. 4E</figref>, a print medium <b>536</b> carries a printed aqueous ink image <b>532</b> with the sacrificial coating <b>512</b> covering the ink image <b>532</b> on the surface of the print medium <b>536</b>. The sacrificial coating <b>512</b> provides protection to the aqueous ink image from scratches or other physical damage while the aqueous ink image <b>532</b> dries on the print medium <b>536</b>.

0080During process <b>700</b>, the printer cleans any residual portions of the sacrificial coating <b>512</b> that may remain on the image receiving surface after the transfixing operation (block <b>724</b>). In one embodiment, a fluid cleaning system <b>395</b> uses, for example, a combination of water and a detergent with mechanical agitation on the image receiving surface to remove the residual portions of the sacrificial coating <b>512</b> from the surface of the belt <b>13</b>. In the printer <b>10</b>, a cleaning blade <b>95</b>, which can be used in conjunction with water, engages the blanket <b>21</b> to remove any residual sacrificial coating <b>512</b> from the image receiving surface <b>14</b>. The cleaning blade <b>95</b> is, for example, a polymer blade that wipes residual portions of the sacrificial coating <b>512</b> from the blanket <b>21</b>.

0081During a printing operation, process <b>700</b> returns to the processing described above with reference to block <b>704</b> to apply the hydrophilic, wet sacrificial coating composition to the image receiving surface, print additional aqueous ink images, and transfix the aqueous ink images to print media for additional printed pages in the print process. The illustrative embodiment of the printer <b>10</b> operates in a “single pass” mode that forms the dried layer, prints the aqueous ink image and transfixes the aqueous ink image to a print medium in a single rotation or circuit of the intermediate transfer member. In alternative embodiments, an inkjet employs a multi-pass configuration where the image receiving surface completes two or more rotations or circuits to form the dried layer and receive the aqueous ink image prior to transfixing the printed image to the print medium.

0082In some embodiments of the process <b>700</b>, the printer forms printed images using a single layer of ink such as the ink that is depicted in <figref idref="DRAWINGS">FIG. 4C</figref>. In the printer <b>10</b>, however, the multiple printhead modules enable the printer to form printed images with multiple colors of ink. In other embodiments of the process <b>700</b>, the printer forms images using multiple ink colors. In some regions of the printed image, multiple colors of ink may overlap in the same area on the image receiving surface, forming multiple ink layers on the hydrophilic composition layer. The method steps in <figref idref="DRAWINGS">FIG. 3</figref> can be applied to the multiple ink layer circumstance with similar results.

EXAMPLES

Example 1

Oil Emulsion Preparation

0083Five oil emulsions were prepared by loading a silicone oil, Wacker AK 500 available from Wacker Chemie AG, (viscosity 500 cps) into TERGITOL TMN-6 surfactant. The loading levels are 2.5%, 5%, 7.5%, 10% and 20%. The oil-surfactant mixture was mixed using a Polytron at speed of 7000 rpm at room temperature for 1 minute. Some oil loaded at 20% was separated from surfactant. All the other 4 mixtures were very stable over a few days.

Example 2

Undercoat Compositions

0084The formulations of Table 1 were prepared with BASF acrylic latexes and either an oil emulsion or Tergitol TMN-6 (no oil, surfactant only). The formulations of Example 2A and Comparative Example 2A included Joncryl® 74-A, which is a soft film forming acrylic emulsion that provides film formation and excellent rub, water, and grease resistance to ink, overprint varnish, and functional packaging coating formulations. The formulations of Example 2B and Comparative Example 2B included Joncryl® 77, which is a hard film forming that provides film formation and printability to ink and overprint varnish formulations. The oil emulsions of Examples 2A and 2B were prepared with 10% AK500 silicone oil and 90% Tergitol TMN-6 surfactant. All these solutions were very stable.

0085<tables id="TABLE-US-00001" num="00001"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE 1</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>BASF Acrylic Latexes - oil emulsion vs. TMN-6 only</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="4"><colspec colname="1" colwidth="56pt" align="left" /><colspec colname="2" colwidth="42pt" align="left" /><colspec colname="3" colwidth="35pt" align="left" /><colspec colname="4" colwidth="84pt" align="left" /><tbody valign="top"><row><entry /><entry>Latexes</entry><entry>Humectant</entry><entry /></row><row><entry>Sample ID</entry><entry>Description</entry><entry>Loading</entry><entry>Loading</entry></row><row><entry namest="1" nameend="4" align="center" rowsep="1" /></row><row><entry>2A-Oil</entry><entry>Joncryl 74A</entry><entry>Sorbitol</entry><entry>32.25% Joncryl 74A +</entry></row><row><entry /><entry>BASF latex</entry><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry /><entry /><entry /><entry>water + 025% oil emulsion</entry></row><row><entry>Comparative</entry><entry /><entry /><entry>31.25% Joncryl 74A +</entry></row><row><entry>Example 2A -</entry><entry /><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry>No Oil</entry><entry /><entry /><entry>water + 0.25% TMN-6</entry></row><row><entry>2B-Oil</entry><entry>Joncryl 77</entry><entry>Sorbitol</entry><entry>31.25% Joncryl 77 +</entry></row><row><entry /><entry>BASF latex</entry><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry /><entry /><entry /><entry>water + 0.25% oil emulsion</entry></row><row><entry>Comparative</entry><entry /><entry /><entry>31.25% Joncryl 77 +</entry></row><row><entry>Example 2B-</entry><entry /><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry>No Oil</entry><entry /><entry /><entry>water + 0.25% TMN-6</entry></row><row><entry namest="1" nameend="4" align="center" rowsep="1" /></row></tbody></tgroup></table></tables>

Example 3

Undercoat Composition

0086The formulations of Table 2 were prepared with Celanese latexes and either an oil emulsion or a TMN-6 surfactant (no oil, surfactant only). The formulations of Example 3A and Comparative Example 3A included RESYN 2920, which is an emulsion comprising an organic acrylic polymer and inorganic silica. The two phases of this emulsion are chemically linked to insure homogeneous distribution. The formulations of Examples 3B and 3C and Comparative Examples 3B and 3C included Dur-O-Cryl 69A, which is a water-based acrylic polymer with self-crosslinking functionality. The oil emulsions were all prepared with 10% AK500 silicone oil and 90% Tergitol TMN-6 surfactant. All these solutions were very stable.

0087<tables id="TABLE-US-00002" num="00002"><table frame="none" colsep="0" rowsep="0"><tgroup align="left" colsep="0" rowsep="0" cols="1"><colspec colname="1" colwidth="217pt" align="center" /><thead><row><entry namest="1" nameend="1" rowsep="1">TABLE 2</entry></row></thead><tbody valign="top"><row><entry namest="1" nameend="1" align="center" rowsep="1" /></row><row><entry>Celanese Latexes - oil emulsion vs. TMN-6 only</entry></row></tbody></tgroup><tgroup align="left" colsep="0" rowsep="0" cols="3"><colspec colname="1" colwidth="49pt" align="left" /><colspec colname="2" colwidth="63pt" align="left" /><colspec colname="3" colwidth="105pt" align="left" /><tbody valign="top"><row><entry /><entry>Latexes</entry><entry /></row><row><entry>Sample ID</entry><entry>Description</entry><entry>Solution Preparation</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row><row><entry>3A-Oil</entry><entry>Resyn 2920</entry><entry>31.25% Resyn 2920 + 18.75%</entry></row><row><entry /><entry>Celanese latex</entry><entry>glycerol + 50% DI water +</entry></row><row><entry /><entry /><entry>0.25% oil emulsion</entry></row><row><entry>Comparative</entry><entry /><entry>31.25% Resyn 2920 + 18.75%</entry></row><row><entry>Example 3A-</entry><entry /><entry>glycerol + 50% DI water +</entry></row><row><entry>No Oil</entry><entry /><entry>0.25% TMN-6</entry></row><row><entry>3B-Oil</entry><entry>Dur-O-Cryl 69A</entry><entry>31.25% Dur-O-Cryl 69A +</entry></row><row><entry /><entry>Celanese latex</entry><entry>18.75% glycerol + 50% DI</entry></row><row><entry /><entry /><entry>water + 0.25% oil emulsion</entry></row><row><entry>Comparative</entry><entry /><entry>31.25% Dur-O-Cryl 69A +</entry></row><row><entry>Example 3B-</entry><entry /><entry>18.75% glycerol + 50% DI</entry></row><row><entry>No Oil</entry><entry /><entry>water + 0.25% TMN-6</entry></row><row><entry>3C-Oil</entry><entry /><entry>31.25% Dur-O-Cryl 69A +</entry></row><row><entry /><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry /><entry /><entry>water + 0.25% oil emulsion</entry></row><row><entry>Comparative</entry><entry /><entry>31.25% Dur-O-Cryl 69A +</entry></row><row><entry>Example 3C-</entry><entry /><entry>18.75% sorbitol + 50% DI</entry></row><row><entry>No Oil</entry><entry /><entry>water + 0.25% TMN-6</entry></row><row><entry namest="1" nameend="3" align="center" rowsep="1" /></row></tbody></tgroup></table></tables>

Example 4

Coating Process

0088Each of the undercoat solutions prepared above were coated on blanket substrate using anilox roll 165Q13 by hand. The substrate was made from fluorinated polymer G621 with A0700 as crosslinker. The hotplate is setup at 60° C. while the substrate temperature is around 50° C. The wet film thickness is around 4-5 microns and the dry film thickness is around 500 nm to 1.5 microns. The coated films were dried in an oven at 60° C. for 30 seconds.

Example 5

Optical Microscope Images—Film Forming Property Evaluation

0089In order to make ink to have good wetting and spreading on undercoat film, it is desirable to achieve a continuous uniform film with undercoat solution. <figref idref="DRAWINGS">FIG. 5</figref> shows optical microscope images taken of films made from the compositions of Examples 3A and 3B, which were coated on G621 blanket substrates.

0090Examples 3A and 3B were prepared using the same humectant (glycerol) but different latexes from Celanese. A Resyn 2920 latex was used in the Example 3A formulation; Dur-O-Cryl 69A was used in the Example 3B formulation. The surface uniformity for both formulations was very similar, as shown by the optical microscope images of <figref idref="DRAWINGS">FIG. 5</figref>.

Example 6

Air Brush Transfer Test

0091Collin ink PWK-1223 was used for transfer test. The ink was sprayed on the coated blanket by air brush. The transfer condition was 320° F., 50 psi and 5 seconds dwell time. The ink was transferred from blanket to 120 gsm Digital Color Elite Gloss paper.

0092The group images of <figref idref="DRAWINGS">FIG. 6</figref> show the transfer test results for two formulations, the first made with BASF latex Joncryl <b>74</b>A loaded with sorbitol (Example 2A above) and the second made with Celanese latex Resyn 2920 loaded with glycerol (Example 3A). The top image is the blanket after transfer and the bottom image is the DCEG paper after ink transfer. There is a lot of residual ink on blanket for formulation without oil emulsion. The ink transfer was dramatically improved after loaded with oil emulsion.

0093Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein.

0094While the present teachings have been illustrated with respect to one or more implementations, alterations and/or modifications can be made to the illustrated examples without departing from the spirit and scope of the appended claims. In addition, while a particular feature of the present teachings may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular function. Furthermore, to the extent that the terms “including,” “includes,” “having,” “has,” “with,” or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” Further, in the discussion and claims herein, the term “about” indicates that the value listed may be somewhat altered, as long as the alteration does not result in nonconformance of the process or structure to the illustrated embodiment. Finally, “exemplary” indicates the description is used as an example, rather than implying that it is an ideal.

0095It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompasses by the following claims.